Busbar assembly for vehicle traction battery

ABSTRACT

A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 14/685,888filed Apr. 14, 2015, now U.S. Pat. No. 10,403,875 issued Sep. 3, 2019,the disclosure of which is hereby incorporated in its entirety byreference herein.

TECHNICAL FIELD

This disclosure relates to busbars and busbar assemblies holders forvehicle traction batteries.

BACKGROUND

Vehicles such as battery-electric vehicles (BEVs), plug-inhybrid-electric vehicles (PHEVs), mild hybrid-electric vehicles (MHEVs),or full hybrid-electric vehicles (FHEVs) contain an energy storagedevice, such as a high voltage (HV) battery, to act as a propulsionsource for the vehicle. The HV battery may include components andsystems to assist in managing vehicle performance and operations. The HVbattery may also include one or more arrays of battery cellsinterconnected electrically between battery cell terminals andinterconnector busbars.

SUMMARY

A vehicle traction battery assembly includes a pair of battery cells anda busbar. Each of the battery cells has a terminal and a pair of ridgeson either side of the terminal defining a valley therebetween. Thebusbar spans between the cells and defines a pair of arms each having atrough member sized to sit within one of the valleys and a terminalaperture to receive one of the terminals such that the busbarelectrically connects the terminals. The trough member may define aheight greater than a height defined by the ridges. The busbar may spanbetween the cells such that the busbar covers at least a portion ofupper surfaces defined by each of the cells. The busbar may furtherinclude a tab defining a volumetric area based on a predetermined amountof electrical current to flow therethrough. At least one of the terminalapertures may be spaced in between outer edges of the respective armssuch that a first and second surface area provide space sufficient forweld spots on either side of the terminal aperture. Each of the arms mayfurther define a clamp zone spaced apart from the respective troughmembers to receive a clamping load. The pair of ridges and busbar may beshaped to at least partially interlock with one another.

A vehicle traction battery assembly includes two battery cells and abusbar. Each of the battery cells has a terminal and a first raisedportion. The busbar is sized to cover at least a portion of each of thecells and defines a second raised portion and a pair of apertures eachsized to receive a portion of one of the terminals. The dimensions ofthe portions are such that the busbar interlocks with the cells when theterminals extend through the terminal apertures. The first raisedportions may each define a height greater than a height defined by thesecond raised portion. The busbar may further define a pair of cutoutsopposite one another and located at a central region of the busbar. Atleast one of the pair of apertures may be spaced apart from an outeredge of the busbar such that a first and second surface area on eitherside of the aperture provide space for weld spots. The apertures andraised portions may be arranged with one another to promote flushcontact between a surface of the busbar and an upper surface of thebattery cells.

A vehicle traction battery assembly includes a pair of battery cells, apair of flanges, and a busbar. Each of the battery cells has a terminaland defines a first mount feature proximate to the terminal and a firstlocating feature. Each of the flanges defines a second mount feature, afirst locating feature, and a first terminal aperture. The busbardefines a second locating feature having a second terminal aperture. Themount features are arranged with one another such that each flangepartially interlocks with a corresponding battery cell, and the locatingfeatures are sized to promote flush contact between the flanges andbusbar only when the terminals extend through the apertures inregistration with one another. The first mount feature may be a pair ofpins extending from the cell and the second mount feature may be a pairof pin apertures sized to receive the pins. The first locating featuremay be a pair of extrusions defining a valley therebetween and thesecond locating feature may be a member sized for disposal within thevalley to promote electrical communication between the terminals. Thefirst locating feature may be a raised portion and define a mountain andthe second locating feature is a cap for the mountain. The shape of thesecond mount feature may be based on contours of at least one of thebattery cells. The first locating feature may define a height relativeto at least one of the battery cells which is less than a height definedby the second locating feature relative to the at least one of thebattery cells.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example of a battery electricvehicle.

FIG. 2 is a perspective view of an example of a portion of a tractionbattery and a thermal management system.

FIG. 3A is an exploded, perspective view of an example of a busbarassembly and a pair of battery cells.

FIG. 3B is a perspective view of the busbar assembly of FIG. 3A shownmounted to the pair of battery cells of FIG. 3A.

FIG. 3C is a side view, in cross-section, of a portion of the busbarassembly and the pair of battery cells of FIG. 3A.

FIG. 4 is an exploded, perspective view of an example of a busbarassembly and a pair of battery cells.

FIG. 5A is an exploded, perspective view of an example of a busbarassembly and a pair of battery cells.

FIG. 5B is a perspective view of the busbar assembly of FIG. 5A shownmounted to the pair of battery cells of FIG. 5A.

FIG. 5C is a side view, in cross-section, of a portion of the example ofthe busbar assembly and the pair of battery cells of FIG. 5A.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It is to beunderstood, however, that the disclosed embodiments are merely examplesand other embodiments can take various and alternative forms. Thefigures are not necessarily to scale; some features could be exaggeratedor minimized to show details of particular components. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a representative basis forteaching one skilled in the art to variously employ embodiments of thepresent disclosure. As those of ordinary skill in the art willunderstand, various features illustrated and described with reference toany one of the figures can be combined with features illustrated in oneor more other figures to produce embodiments that are not explicitlyillustrated or described. The combinations of features illustratedprovide representative embodiments for typical applications. Variouscombinations and modifications of the features consistent with theteachings of this disclosure, however, could be desired for particularapplications or implementations.

FIG. 1 depicts a schematic of an example of a plug-in hybrid-electricvehicle (PHEV). A vehicle 12 may comprise one or more electric machines14 mechanically connected to a hybrid transmission 16. The electricmachines 14 may be capable of operating as a motor or a generator. Inaddition, the hybrid transmission 16 is mechanically connected to anengine 18. The hybrid transmission 16 is also mechanically connected toa drive shaft 20 that is mechanically connected to the wheels 22. Theelectric machines 14 can provide propulsion and deceleration capabilitywhen the engine 18 is turned on or off. The electric machines 14 mayalso act as generators and can provide fuel economy benefits byrecovering energy that would normally be lost as heat in the frictionbraking system. The electric machines 14 may also provide reducedpollutant emissions since the vehicle 12 may be operated in electricmode or hybrid mode under certain conditions to reduce overall fuelconsumption of the vehicle 12.

A traction battery or battery pack 24 stores and provides energy thatcan be used by the electric machines 14 or other vehicle 12 components.The traction battery 24 typically provides a high voltage DC output fromone or more battery cell arrays, sometimes referred to as battery cellstacks, within the traction battery 24. The high voltage DC output mayalso be converted to a low voltage DC output for applications such asvehicle stop/start. The battery cell arrays may include one or morebattery cells. The traction battery 24 may be electrically connected toone or more power electronics modules 26 through one or more contactors(not shown). The one or more contactors isolate the traction battery 24from other components when opened and connect the traction battery 24 toother components when closed. The power electronics module 26 is alsoelectrically connected to the electric machines 14 and provides theability to bi-directionally transfer electrical energy between thetraction battery 24 and the electric machines 14. For example, a typicaltraction battery 24 may provide a DC voltage while the electric machines14 may require a three-phase AC voltage to function. The powerelectronics module 26 may convert the DC voltage to a three-phase ACvoltage as required by the electric machines 14. In a regenerative mode,the power electronics module 26 may convert the three-phase AC voltagefrom the electric machines 14 acting as generators to the DC voltagerequired by the traction battery 24. The description herein is equallyapplicable to a pure electric vehicle or other hybrid vehicles. For apure electric vehicle, the hybrid transmission 16 may be a gear boxconnected to an electric machine 14 and the engine 18 may not bepresent.

In addition to providing energy for propulsion, the traction battery 24may provide energy for other vehicle electrical systems. A typicalsystem may include a DC/DC converter module 28 that converts the highvoltage DC output of the traction battery 24 to a low voltage DC supplythat is compatible with other vehicle loads. Other high-voltage loads,such as compressors and electric heaters, may be connected directly tothe high-voltage without the use of a DC/DC converter module 28. In atypical vehicle, the low-voltage systems are electrically connected toan auxiliary battery 30 (e.g., 12V battery).

A battery electrical control module (BECM) 33 may be in communicationwith the traction battery 24. The BECM 33 may act as a controller forthe traction battery 24 and may also include an electronic monitoringsystem that manages temperature and charge state of each of the batterycells. The traction battery 24 may have a temperature sensor 31 such asa thermistor or other temperature gauge. The temperature sensor 31 maybe in communication with the BECM 33 to provide temperature dataregarding the traction battery 24. The temperature sensor 31 may also belocated on or near the battery cells within the traction battery 24. Itis also contemplated that more than one temperature sensor 31 may beused to monitor temperature of the battery cells.

The vehicle 12 may be, for example, an electric vehicle such as a PHEV,a FHEV, a MHEV, or a BEV in which the traction battery 24 may berecharged by an external power source 36. The external power source 36may be a connection to an electrical outlet. The external power source36 may be electrically connected to electric vehicle supply equipment(EVSE) 38. The EVSE 38 may provide circuitry and controls to regulateand manage the transfer of electrical energy between the power source 36and the vehicle 12. The external power source 36 may provide DC or ACelectric power to the EVSE 38. The EVSE 38 may have a charge connector40 for plugging into a charge port 34 of the vehicle 12. The charge port34 may be any type of port configured to transfer power from the EVSE 38to the vehicle 12. The charge port 34 may be electrically connected to acharger or on-board power conversion module 32. The power conversionmodule 32 may condition the power supplied from the EVSE 38 to providethe proper voltage and current levels to the traction battery 24. Thepower conversion module 32 may interface with the EVSE 38 to coordinatethe delivery of power to the vehicle 12. The EVSE connector 40 may havepins that mate with corresponding recesses of the charge port 34.

The various components discussed may have one or more associatedcontrollers to control and monitor the operation of the components. Thecontrollers may communicate via a serial bus (e.g., Controller AreaNetwork (CAN)) or via discrete conductors.

The battery cells, such as a prismatic cell, may include electrochemicalcells that convert stored chemical energy to electrical energy.Prismatic cells may include a housing, a positive electrode (cathode)and a negative electrode (anode). An electrolyte may allow ions to movebetween the anode and cathode during discharge, and then return duringrecharge. Terminals may allow current to flow out of the cell for use bythe vehicle. When positioned in an array with multiple battery cells,the terminals of each battery cell may be aligned with opposingterminals (positive and negative) adjacent to one another and a busbarmay assist in facilitating a series connection between the multiplebattery cells. The battery cells may also be arranged in parallel suchthat similar terminals (positive and positive or negative and negative)are adjacent to one another. For example, two battery cells may bearranged with positive terminals adjacent to one another, and the nexttwo cells may be arranged with negative terminals adjacent to oneanother. In this example, the busbar may contact terminals of all fourcells. The traction battery 24 may be heated and/or cooled using aliquid thermal management system, an air thermal management system, orother method as known in the art.

The traction battery 24 may be heated and/or cooled using a liquidthermal management system, an air thermal management system, or othermethod as known in the art. In one example of a liquid thermalmanagement system and now referring to FIG. 2, the traction battery 24may include a battery cell array 88 shown supported by a thermal plate90 to be heated and/or cooled by a thermal management system. Thebattery cell array 88 may include a plurality of battery cells 92positioned adjacent to one another and structural support components.The DC/DC converter module 28 and/or the BECM 33 may also requirecooling and/or heating under certain operating conditions. A thermalplate 91 may support the DC/DC converter module 28 and BECM 33 andassist in thermal management thereof. For example, the DC/DC convertermodule 28 may generate heat during voltage conversion which may need tobe dissipated. Alternatively, thermal plates 90 and 91 may be in fluidcommunication with one another to share a common fluid inlet port andcommon outlet port.

In one example, the battery cell array 88 may be mounted to the thermalplate 90 such that only one surface, of each of the battery cells 92 isin contact with the thermal plate 90. The thermal plate 90 andindividual battery cells 92 may transfer heat between one another toassist in managing the thermal conditioning of the battery cells 92within the battery cell array 88 during vehicle operations. Uniformthermal fluid distribution and high heat transfer capability are twothermal plate 90 considerations for providing effective thermalmanagement of the battery cells 92 within the battery cell arrays 88 andother surrounding components. Since heat transfers between thermal plate90 and thermal fluid via conduction and convection, the surface area ina thermal fluid flow field is important for effective heat transfer,both for removing heat and for heating the battery cells 92 at coldtemperatures. For example, charging and discharging the battery cellsgenerates heat which may negatively impact performance and life of thebattery cell array 88 if not removed. Alternatively, the thermal plate90 may also provide heat to the battery cell array 88 when subjected tocold temperatures.

The thermal plate 90 may include one or more channels 93 and/or a cavityto distribute thermal fluid through the thermal plate 90. For example,the thermal plate 90 may include an inlet port 94 and an outlet port 96that may be in communication with the channels 93 for providing andcirculating the thermal fluid. Positioning of the inlet port 94 andoutlet port 96 relative to the battery cell arrays 88 may vary. Forexample and as shown in FIG. 2, the inlet port 94 and outlet port 96 maybe centrally positioned relative to the battery cell arrays 88. Theinlet port 94 and outlet port 96 may also be positioned to the side ofthe battery cell arrays 88. Alternatively, the thermal plate 90 maydefine a cavity (not shown) in communication with the inlet port 94 andoutlet port 96 for providing and circulating the thermal fluid. Thethermal plate 91 may include an inlet port 95 and an outlet port 97 todeliver and remove thermal fluid. Optionally, a sheet of thermalinterface material (not shown) may be applied to the thermal plate 90and/or 91 below the battery cell array 88 and/or the DC/DC convertermodule 28 and BECM 33, respectively. The sheet of thermal interfacematerial may enhance heat transfer between the battery cell array 88 andthe thermal plate 90 by filling, for example, voids and/or air gapsbetween the battery cells 92 and the thermal plate 90. The thermalinterface material may also provide electrical insulation between thebattery cell array 88 and the thermal plate 90. A battery tray 98 maysupport the thermal plate 90, the thermal plate 91, the battery cellarray 88, and other components. The battery tray 98 may include one ormore recesses to receive thermal plates.

Different battery pack configurations may be available to addressindividual vehicle variables including packaging constraints and powerrequirements. The battery cell array 88 may be contained within a coveror housing (not shown) to protect and enclose the battery cell array 88and other surrounding components, such as the DC/DC converter module 28and the BECM 33. The battery cell array 88 may be positioned at severaldifferent locations including below a front seat, below a rear seat, orbehind the rear seat of the vehicle, for example. However, it iscontemplated the battery cell arrays 88 may be positioned at anysuitable location in the vehicle 12.

The battery cells, such as a prismatic cell, may include electrochemicalcells that convert stored chemical energy to electrical energy.Prismatic cells may include a housing, a positive electrode (cathode)and a negative electrode (anode). An electrolyte may allow ions to movebetween the anode and cathode during discharge, and then return duringrecharge. Terminals may allow current to flow out of the cell for use bythe vehicle. When positioned in an array with multiple battery cells,the terminals of each battery cell may be aligned with opposingterminals (positive and negative) adjacent to one another and a busbarmay assist in facilitating a series connection between the multiplebattery cells. The battery cells may also be arranged in parallel suchthat similar terminals (positive and positive or negative and negative)are adjacent to one another. For example, two battery cells may bearranged with positive terminals adjacent to one another, and the nexttwo cells may be arranged with negative terminals adjacent to oneanother. In this example, the busbar may contact terminals of all fourcells.

FIGS. 3A through 3C show an example of a busbar and a pair of batterycells for use with a vehicle traction battery assembly. A busbar 100 mayinclude features to assist in electrically connecting adjacent batterycells and to assist in facilitating a laser weld operation to secure thebusbar 100 to terminals of the battery cells. For example, the busbar104 may include a pair of arms 110 and a tab 112. Each of the arms 110may define a member 116 and a terminal aperture 118 therein. The member116 may also be referred to as a trough or weld member herein. The tab112 may extend in a first vertical direction relative to the arms 110.It is contemplated that the tab 112 may have other configurations inaccordance with a surrounding environment and/or packaging constraints.For example, the tab 112 may extend at an angle relative to the arms 110or may extend in a second vertical direction relative to the arms 110.The tab 112 may define a volumetric area based on a predetermined amountof electricity which will flow between terminals of battery cells.

The busbar 100 may span between a first battery cell 122 and a secondbattery cell 124 to at least partially cover an upper face defined byeach of the battery cells. The first battery cell 122 includes a firstterminal 126 and the second battery cell 124 includes a second terminal128. In this example, each of the arms 110 may be directly adjacent oneanother forming a horseshoe shape. It is contemplated that in otherconfigurations the arms 110 may be connected to one another, may definea single component, or may be of another shape. A horseshoe shape of thebusbar 100 may assist in providing flexibility of the busbar 100 toaccommodate for varying heights of adjacent battery cells. The busbar100 may assist in conducting electricity between the first terminal 126and the second terminal 128. The bus bar 100, the first battery cell122, and the second battery cell 124 may include features to assist inlocating one another and to facilitate weld operations duringinstallation.

For example, the first battery cell 122 and the second battery cell 124may each define a pair of features 130 spaced apart from one another andlocated on either side of the respective terminal. The features 130 mayalso be referred to as ridges or extensions herein. The pair of features130 may define a valley 131 sized to receive the respective members 116of the busbar 100. Various shapes and forms of the pair of features 130may be available. For example, the features 130 may define triangularprism shapes about the respective terminals. Under certain conditions,the pair of features 130 may only partially extend across the respectivebattery cell or the pair of features 130 may define other shapes such astriangular prisms. In order to facilitate a proper weld, it may bepreferable for the busbar 100 to directly contact and be substantiallyflush with a surface of the valley 131. The size and shape of the member116 and the valley 131 may be such that each member 116 partiallyinterlocks with the valley 131. The member 116 may be sized such thatspace is provided on either side there of as a clamp zone to facilitatea clamping operation during installation. The size and shape of themember 116 and the valley 131 may be such that the member 116 contacts alower surface within the valley 131 and between the features 130 toassist in facilitating an electrical connection between the firstterminal 126 and the second terminal 128.

For example and as shown in FIG. 3C, a height of each member 116 may berepresented by a distance 136. A height of each feature 130 may berepresented by a distance 138. The distance 136 may be a height greaterthan the distance 138 to ensure the member 116 contacts the surfacewithin the valley 131. Each member 116 and each of the respectivefeatures 130 may further be shaped to facilitate a partiallyinterlocking relationship to assist in locating one another duringinstallation. For example, portions of each member 116 may be shaped tomirror portions of the respective features 130.

A location of the terminal apertures 118 on the arms 110 may furtherassist in locating the busbar 100 to the battery cells and infacilitating the weld operation therebetween. The terminal apertures 118may be sized to receive the respective first terminal 126 and the secondterminal 128 such that the members 116 may be oriented for insertionwithin the respective valleys 131. With regard to assisting infacilitating weld operations, the terminal aperture 118 may be spaced inbetween edges of the respective arm 110 to provide sufficient space fora weld spot, such as laser weld spots 140 which are represented by hashmarks in FIG. 3B. Other forms of welding which may secure the busbar 100to the first battery cell 122 and the second battery cell 124 includeresistance, ultrasonic, and spot. The location of the terminal apertures118 may also provide sufficient space for the weld spots 140 toaccommodate a regression or subsequent weld in the event of a failedinitial weld.

FIG. 4 shows another example of a busbar and a pair of battery cells foruse with a vehicle traction battery assembly. In this example, a busbarassembly may include a busbar 202 and a first flange 206 a and a secondflange 206 b. The busbar 202 may define a first terminal aperture 218 aand a second terminal aperture 218 b sized to receive terminals and afirst arm 210 a having a first trough 216 a and a second arm 210 bhaving a second trough 216 b. The busbar assembly, a first battery cell222, and a second battery cell 224 may include locating features toassist in securing the busbar assembly to the battery cells. Forexample, first flange 206 a may define a first set of apertures 240 aand 240 b and second flange 206 b may define a second set of apertures240 c and 240 d. It is contemplated that multiple configurations of thefirst set of apertures 240 a and 240 b and the second set of apertures2′1′1240 c and 240 d are available. A first flange terminal aperture 244a is defined by the first flange 206 a and a second flange terminalaperture 244 b is defined by the second flange 206 b. In this example,the first aperture 240 a receives the first pin 260 a and the secondaperture 240 b receives the second pin 260 b. The pins 260 a and 260 bare provided on of the first battery cell 222. A third aperture 240 creceives the third pin 260 c and the fourth aperture receives the fourthpin 260 d. Pins 240 c and 240 d are provided on the second battery cell224. The first flange terminal apertures 244 a receives the firstterminal 226 and the second flange terminal aperture 244 b receives thesecond terminal 228. Terminal caps 229 may be configured to cover therespective terminals thereunder. The busbar 202 and each flange 206 aand 206 b may be arranged with one another such that the respectiveterminal apertures 218 a and 218 b are in at least partial registrationwith the flange terminal apertures 244 a and 244 b, respectively, andreceive the first terminal 226 and the second terminal 228 therethrough,respectively.

Each flange 206 a and 206 b may further define a locating feature toassist in mounting the busbar 202 thereto. For example, the first flange206 a may include a first pair of ribs 268 a and the second flange 206 bmay include a second pair of ribs. The pairs of ribs 268 a and 268 b arespaced apart from one another and are sized to receive the troughmembers 216 a and 216 b of the busbar 202. The terminal apertures 218 aand 218 b may be located within the respective trough members 216 a and216 b such that adequate space is provided on either side of theterminal apertures 218 a and 218 b to facilitate a weld as described inthe examples above. The flanges 206 a and 206 b may have multipleconfigurations adaptable to various battery cells which may not includelocating features molded or integrated therein.

FIGS. 5A through 5C show another example of a busbar and a pair ofbattery cells for use with a vehicle traction battery assembly. A busbar300 may include features to assist in electrically connecting adjacentbattery cells and to assist in facilitating a laser weld operation tosecure the busbar 300 to terminals of the battery cells. For example,the busbar 300 may include a raised portion 316 and may define a pair ofterminal apertures 318. The busbar 300 may span between a first batterycell 322 and a second battery cell 324 to at least partially cover aface of each of the battery cells. In this example, the busbar 300defines two cutouts 325 to assist in providing flexibility of the busbar300 to accommodate for varying heights of adjacent battery cells.

The first battery cell 322 includes a first terminal 326 and the secondbattery cell 324 includes a second terminal 328. The busbar 300 mayassist in conducting electricity between the first terminal 326 and thesecond terminal 328. The bus bar 300, the first battery cell 322, andthe second battery cell 324 may include features to assist in locatingone another and to facilitate weld operations during installation. Forexample, the first battery cell 322 and the second battery cell 324 mayeach define a feature 330, such as a mountain feature, located in linewith the respective terminal. The feature 330 may define an extension orridge sized for supporting the raised portion 316 of the busbar 300.Various shapes and forms of the feature 330 may be available. Undercertain conditions, the feature 330 may only partially extend across therespective battery cell or the feature 330 may define other shapes suchas triangular prisms.

In order to facilitate a proper weld, the busbar 300 may directlycontact and be substantially flush with a surface of the feature 330.The size and shape of the raised portion 316 and the feature 330 may besuch that the raised portion 316 partially interlocks with the feature330. The size and shape of the raised portion 316 and the feature 330may be such that the raised portion 316 and the feature 330 partiallyinterlock to assist in facilitating an electrical connection between thefirst terminal 326 and the second terminal 328.

For example and as shown in FIG. 5C, a height of the raised portion 316may be represented by a distance 336. A height of the feature 330 may berepresented by a distance 338. The distance 338 may be greater than thedistance 336 to ensure the raised portion 316 contacts a surface of thefeature 330. The raised portion 316 and the feature 330 may further beshaped to facilitate a partially interlocking relationship to assist inlocating one another during installation. For example, portions of theraised portion 316 may be shaped to mirror portions of the respectivefeature 330.

A location of the terminal apertures 318 on the busbar 300 may furtherassist in locating the busbar 300 to the battery cells and infacilitating the weld operation therebetween. The terminal apertures 318may be sized to receive the respective first terminal 326 and the secondterminal 328 such that the raised portions 316 may be oriented toreceive the respective feature 330. With regard to assisting infacilitating weld operations, the terminal apertures 318 may be spacedin between edges of the busbar 300 to provide sufficient space for aweld spot, such as laser weld spots 340 which are represented by hashmarks in FIG. 5B. Other forms of welding which may secure the busbar 300to the first battery cell 322 and the second battery cell 324 includeresistance, ultrasonic, and spot. The location of the terminal apertures318 may also provide sufficient space for the weld spots 340 toaccommodate a regression or subsequent weld in the event of a failedinitial weld.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms encompassed by the claims.The words used in the specification are words of description rather thanlimitation, and it is understood that various changes can be madewithout departing from the spirit and scope of the disclosure. Aspreviously described, the features of various embodiments can becombined to form further embodiments of the disclosure that may not beexplicitly described or illustrated. While various embodiments couldhave been described as providing advantages or being preferred overother embodiments or prior art implementations with respect to one ormore desired characteristics, those of ordinary skill in the artrecognize that one or more features or characteristics can becompromised to achieve desired overall system attributes, which dependon the specific application and implementation. These attributes caninclude, but are not limited to cost, strength, durability, life cyclecost, marketability, appearance, packaging, size, serviceability,weight, manufacturability, ease of assembly, etc. As such, embodimentsdescribed as less desirable than other embodiments or prior artimplementations with respect to one or more characteristics are notoutside the scope of the disclosure and can be desirable for particularapplications.

What is claimed is:
 1. A vehicle traction battery assembly comprising: afirst battery cell having a first terminal and first and second pinsproximate the first terminal, a second battery cell having a secondterminal and third and fourth pins proximate the second terminal; afirst flange defines a first locating aperture, a second locatingaperture and a first flange terminal aperture, wherein the first pin isreceived in the first locating aperture and the second pin is receivedin the second locating aperture to interlock the first flange with thefirst battery cell, wherein a second flange defines a third locatingaperture, a fourth locating aperture and a second terminal aperture,wherein the third pin is received in the third locating aperture and thefourth pin is received in the fourth locating aperture to interlock thesecond flange with the second battery cell, and wherein each flangeincludes a pair of ribs; and a busbar defining a first busbar terminalaperture and a second busbar terminal aperture, wherein the busbarincludes two troughs, and wherein each of the troughs is receivedbetween one of the pairs of ribs when the first terminal is received inthe first flange terminal aperture and the first busbar terminalaperture, and when the second terminal is received in the second flangeterminal aperture and the second busbar terminal aperture.
 2. Thevehicle traction battery assembly of claim 1, wherein both of the pairsof ribs are extrusions that each define a valley therebetween and eachof the troughs is disposed within one of the valleys to provide anelectrical connection between the first terminal and the secondterminal.